When it's time to rebuild your vintage Ford small-block, the long list of things required can have you examining the checkbook and those credit card balances. While it's true an engine rebuild involves a lot of time and money, you can still realize great performance and enhanced durability at a reasonable price if you plan and build wisely. Did you know you can build a 300-plus-horsepower V-8 for under $2,000?
Building this kind of power doesn't have to cost a fortune if you plan properly and choose the right combination of parts. There are also simple procedures you can perform during the building process that make light work of getting big power for the money. Horsepower and torque are like weight loss programs. We're so busy searching for the easy route that we forget the common sense approach. Diet and exercise is the surest path to weight loss. Choosing the right combination of parts and assembly procedures is the easiest path to making power. It's just simple common sense.
Today we're going to Trans Am Racing where Mark Jeffery will show us what's involved in a properly planned and executed Ford small-block build. We're going to show you how to get the most bang for your buck, and how we found stock replacement parts to be adequate for as much as 300-350 hp.
The engine we're working with sports a '68 C8OE 302 block. We're after a mild-mannered street engine that will still deliver 300-plus horsepower when the pedal hits the metal. To begin with, we will examine our selection of components for this budget build, and then look at some of the more important aspects of engine assembly where extra care will pay dividends in improved reliability and a longer service life.
Budget Parts That Work
This is a well-used '68 C8OE block with the extended cylinder skirts designed to accommodate the 302's longer stroke. That is what makes it different than a '63-'68 289 block. Decking and align boring were not needed. A 0.030-inch overbore has been accomplished. New freeze plugs have been installed. Screw-in oil galley plugs have been installed for reliability. This is all low-buck machine work that accomplishes a lot. | 
Here's our factory 2MA nodular iron crank just back from the machine shop. To clean up any discrepancies at the journals, both the main and rod journals have been machined 0.010-inch undersize. Speed Pro 0.010-inch oversize main and rod bearings get the nod. Any time you have machine work performed, the bottom end must be dynamic balanced. This isn't optional, it's mandatory. | 
We're using 4.030-inch Speed Pro flat-top hypereutectic pistons (PN H120CP) with Teflon-coated skirts for reduced friction and increased compression. Reducing internal friction and increased compression are the keys to power. These pistons are fly-cut to clear up to 1.94-inch intake valves. |
The factory C8AE Ford connecting rods shown here (5.0885-5.0915-inches center-to-center) will easily handle the power. L & R Automotive Supply Company has reconditioned them and installed 5/16-inch ARP bolts, which works well for a 300-horse engine. One option is to have 3/8-inch bolts installed during rod reconditioning, which gets these rods to 289 Hi-Po/Boss 302 specs. This costs only marginally more. | 
Cam selection is an important issue. We've chosen a Crane flat-tappet hydraulic cam and lifter kit (PN 363902). This mild hydraulic kit is for '62-'84 221-302ci Ford small-block engines. This grind offers .456/.484 lift. The advertised duration is 260/270 degrees on 112-degree lobe centers. This is more aggressive than the 289 High Performance factory camshaft. For about $300 more, you can step up to a more aggressive roller camshaft and more power. | 
These are the factory C8OE cylinder head castings for 302-2V engines with 58cc chambers professionally machined by L & R Automotive Supply Company--perfect for our flat-top pistons. These heads have a fresh three-angle valve job with Speed Pro valves and Crane springs, retainers, and keepers. Spring pressure is matched to the cam profile. These are actually Windsor foundry castings, not the Cleveland iron we usually see. Look to Power Heads for CNC-ported iron heads for under $700. Opt for 351W castings from Power Heads and make even more power. |